Insulated tile unit and structure



E. R. POWELL INSULATED TILE UNIT AND STRUCTURE med Nov. 25. 1935 Nov. 2, 1937.

Patented Nov. 2, 1937 VUNITED -STATES PATNT OFFICE 2,991,892 nvsULATED TILE UNIT AND STRUCTURE Edward R. Powell, Alexandria, Ind. Application November 25, 1935, serial No. 51,993 12 (cl. 'z2-31) This invention relates to insulated masonry or, in other words, masonry which transmits relatively little heat in certain directions. 2 It relates particularly to walls, roofs, ceiling and floor slabs .5 which are mechanically strong and which resist the transfer of heat and outer surfaces.

A chief feature of the invention is to provide a structure'for residence building or other purposes which involves the use of ceramic tile or other strong and inexpensive material involving conventional processes in its manufactpre, and insert therein insulating material which insulates in the finished structure as before ser fornfand performs other important functions inthe erection of same.

One object of the invention is to manufacture and assemble composite units which include hard structuralgsheets and frames enclosing relatively 2@ soft lling material, the lling material being firm enough, however, to hold and act as a form for grout or mortar used in the assembly.

` Another object of the invention is to empy in certain relationships structural material s ch as ceramic tile or asbestos wood in combination with such insulating material as minerabwool i bats or various insulating fillers or felts so that the structural material will not transmit heat around the insulating material excessively and 3o yet will make a satisfactory structure.`

Another object of the invention is to provide such composite building units and so assemble or lay them that a wall or slab is formed in one laying operation which is satisfactory in weather 35 resistance, appearance and durability. As added advantages of the preferred forms of the invention, structures are fabricated which resist rot, re, vermin, cracking and in general require little maintenance. Y v

io Thefull nature of the invention will befunderstood readily by referring to the accompanying drawing, the following description and claims.

In the drawing, Fig. 1 isa horizontal section of a wall embodying one form of the invention. 451r Fig. 2 is an elevation of part of the Wall of Fig. 1.

Fig. 3 is a vertical section taken in plane 3 3 of Fig. 2 and in the direction ofthe arrows.

Fig. 4 is a horizontal section of a wall of modi- 50 fiedform. ,V i

Fig. 5 is a vertical section of a slab which em l bodies the invention and is suitable for use as a ceiling,.floor or roof.

Fig. 6 is a vertical section taken in plane 6 5 55 of Fig. 5 in either direction.

thru them between inner y Referring to Fig. 1, Il indicates a hollow tile of conventional material and processing having relatively thin through webs I4 at the ends only. Comparatively large flat sheets of material are exposed on opposite sides of the wall and the intervening space is filled with insulating material I0. Satisfactory materials for the purpose are fired shale or clay tile and mineral wool bats of relatively firm composition and water-repellent character. The tile are laid up employing con- 1i ventional tools and relatively hard mortar l2. A strip of resilient material i3 is laid in the joint and has the eect of interrupting the mortar joint. This material is preferably oiled with an excess of wax or'oil-bearing liquid or other waterrepellent liquid so that it moistens the adjacent webs M of the tile at ila. and thus prevents them from ltransmitting water by capillary or wick action thru the wall. In this way the wall is Well waterproofed since water will not absorb from the tile to the insulating lling under normal conditions. The horizontal mortar joints are l reinforced with metal rods 29, see Fig. 3.

If preferred, the through Webs it of the tile ll before laying may be treated at l la with wax solution or equivalent material to prevent water conduction.

Typical mortar for use in this erection consists of one part Portland cement to four of sand and some plasticizing material such as hydrated lime in lesser proportion, with enough water to make a mortar of desired consistency. Certain ground clays have been used satisfactorily for plastic. izing.l Other compositions may be desirable under special conditions. Y

For vertical reinforcement, a channel is formed in the yielding insulation adjacent the webs of the tile and grout l5 is poured into ,the space thus formed. Vertical rods I6 are inserted into 40 this space or into the grout while still soft.

A wall thus,.builtV although employing inexpensive materials has unusual merit. It may be lifted in sections of considerable size by eyes or hooks attached to or formed in the ends of rods I6. It will permit assembling horizontally and standing up without fracture.V It permits streams of water to run down one side for long periods of time without damage or wetting the other side. It may be assembled in a shop in panels 5o and shipped to the building site. In general, it involves about the minimum of material for a Wall of great strength and durability since each material in it performs a valuable anddependent function. It is preferably built of durable retreated mineral Wool panded after mixing with oil prooi materials and, if properly built,l is highly resistant to all common forms of destruction.

The insulating material lli should be highly water-repellent and readily formable into channels for the grout. With certain grades of bats, it has been demonstrated that moisture will not absorb from the tile to the bat. Usually 11/2 to 8 per cent of wax, resin, grease or combinations thereof added evenly to clay or mineral wool have the effect of rendering same relatively non-absorbent or Watan-repellent. Clay tile is commonly of finer porosity than the cumstance aids in arresting the capillary travel of moisture through the Wall. Other insulating fills may also be used such as treated expanded clay, treated cork and jute and cotton felt's if stiened' slightly.

Ii the insulation or fill in the wall will not retain its shape, a channel of sheet material 2id may be used to confine the grout it. Such loose fills may be poured into each tile after setting. Mineral wool bats are preferably inserted before laying the tile.

Expanded clay for a ll of this type may be made by the process described in my application and is dried but may be left uniired so that the oil acts as a binder and waterproofing.

In the assembled unit shown in Fig. d, the tile is formed of twochannels i? and 2S secured with dowels 2l. A layer of resilient material 2li such 'no excess of oil in this construction. The ad- Vantages of this structure over that illustrated in Figs'. l to 3, inclusive, are that the interruption of heat conduction lis more complete. The channels il and t may be rolled after extruding in the manufacture to secure more variety of texture than is possible with hollow tile.

merely a sort o suspended closure for the spaces if such an arrangement is desired.

The consistency or" the interrupting material strip i3 in each formed between adjacent units in spite of slight cracking of the structure. 'I'he strip I3 should be under some compression in the finished structure. It may be laid on the tile before or after spreading the mortar. In a joint thus constructed the mortar alone is not depended on for a seal but is primarily depended upon for a bond.

The Water-repellent nature of the insulation permits mortar to be with.' The insulation will not absorb water appreciably from the wet mortar. 'I'his would be undesirable since the water is mortar to complete the setting and is undesirable in the insulation. A

adapted to resist The slab of Figs. 5A and 6 is bending and may be used to span the usual width of residence rooms for floors and roofs. 'Ihe top or compression member 23 is of heavy Walled tile made in conventional manner. The lighter tile 26 is suspended from flange 25 of tile Z3 by insulating material which cirties 36. These may be metal, tile material or asbestos Wood. Insulating material i0 is used as in the walls. The tile 23 are preferably made smaller than tile 26 so that there is room for a substantial reinforced joint or beam 3l enclosing reinforcing rod 29. The `ioints thus formed act as beams or joists to carry the slab. The insulating material, if not self-sustaining on the edges, may be contained in cardboard forms 32. For nearly complete thermal separation of the upper and lower tile, felt pads or equivalent material 2li should be used. Strips of hair felt or mineral wool felt are satisfactory for these purposes. Tile 2E may be perforated to admit sound and thus form an acoustical treatment in combination with the insulation iii, which may be selected for sound absorbing as well as thermal properties. Members 2| may be pins, dowels or bolts according to the nature ofthe ties 3@ which are to be secured to the anges or webs.

The upper tile are preferably' coated with a thin layer of mortar or concrete 2l for leveling up. This is in turn treated or coated with rnaterial iid for flooring or roofing service. In this is complete If desired, light metal may be used running for erection purposes.

inforcement, but reinforcement is optional in vertical walls. Closures of some `is not fully prefrabricated or standardized. IlUsing such ingenuity does not constitute a deto theA appended claims.

The invention claimed is:

y manufacture, including hard structural inner and .tween the shells,` and means on outer shells with relative little web material connecting same, water repellent insulating material substantially illling the enclosed space bethe through webs to prevent capillary conduction. of water therethrough.

2. A unit as defined by claim l, characterized by the insulating material including a channel and by the addition of grout therein formation for. the purpose set forth.

3. A hollow tile building unit as an article of manufacture, including hard structural inner and outer sheets with relatively little web material .mentioned for suspending the connecting same, the web material consisting of independentA flanges' formed integral with the sheets, means mechanically holding the -fianges in spaced relation, and w ter repellent means interposed in the rst mentioned means for separating the flanges susbtantially as described.

4. A unit as defined by claim 3, characterized by the addition of a preassembled water repellentl insulation substantially illling the sheets.

5. A unit adapted for assembling into horizontal load bearing slabs, including a heavy compression 'resisting tile, a closure tile lighter than the compression tile, means suspended from the rst closure tile, and water repellent insulating material substantially iilling the space between these tiles and adapted to prevent grout entrance to the space between these tiles at the joints. l.

6. A structure, including hollow tile units assembled as a single wall, mortar bond joints therebetweenand of interrupted character, and an interrupting resilient material strip under slightcompression and intermediate the inner and outer surfaces of the structure and in all the space between ing the hollow portion of the tile.-

joints for maintaining an interrupting seal in spite of slight cracking at any joint.

'7. A structure as defined by claim 6, characterized by the addition of insulating material substantially filling the hollow portions oi the tile units.

8. A structure including hollow tile units assembled as a single ing material substantially lling the hollow portions of the umts, mortar bond joints of yinterrupted character connecting said units, strips' of resilient material in all mortar joints intermediate the inner and outer surfaces ofthe strucwall, water repellent insulatture, and means upon the through webs of the tile to prevent capillary transmission of water through the single layer structure.

9. A structure as deiined by claim 8, characterized by the addition of reenforcing rods imbedded in certainmortar joints. 10. As an article of manufacture, a'composite building unit including two channel shaped tile units, the flanges of the channels being turned together, means mechanically holding the ilanges together in spaced relation but not intimately contacting, and water repellent. insulating material substantially filling the space enclosed by the two channels. f

11. A horizontal building slab which includes composite units consisting of load bearing tile, decorative tile of greater horizontal dimensions, means suspending the latter from the former, other means thermally insulating the tiles, the

. units being arranged in horizontal series to form beam shaped spaces, and ree'nforced concrete in these spaces, the reenforcement of saidconcrete being near the lower extremities of the beam.

12. As an article of manufacture, a hollow tile of generally hollow rectangular solid shape, the tile being of tired ceramic material, and treated, water repellent, expanded clay substantially nll- EDWARD a. POWELL.: 

